Machine for electrically welding wires



March 17, 1936. w 3 AD 2,034,560

MACHINE FOR ELECTRICALLY WELDING WIRES Filed Nov. 28, 1934 3 Sheets-Sheet l Inventor: 7 William D. Bumstead,

Hls Attorney.

March 17, 1936. w. EAD 2,034,560

MACHINE FOR ELECTRICALLY WELDING WIRES Filed Nov 28, 1934 3 Sheets-$heet 2 Inventor: William D. Bumstead,

His ttorney.

March 17,1936. w D. TEAD I 2,034,560

MACHINE FOR ELECTRICALLY WELDING WIRES Filed Nov. 28, 1954 3 Sheets-Sheet 3 Inventor: WiI I iam D. Bumstead,

's A torney.

Patented-Mar, 1 7, 1936;;

PATENT OFFICE MACHINE Foa ELECTRICALLY WELDING wnms 'William D. Bnmstead, Cleveland, Ohio, assignor to General Electric Company, a corporation of s New York Application November 28, 1934, Serial No. 755,125 10 Claimsr (Cl. 219-4) My invention relates to the welding of wires together in end to end relation and more particularly to machines for weldinglengths of wire 7 together in said relation. Sectional wires are very generally used in lamps, radio tubes and other-similar articles, the sectional construction beingito'provide portions of difierent composition so that the wire will function properly in the portion of the article in which it is located. Be-

cause of the precision construction of these articles and machine manufacturing requirements, these wires are required to be straight and the weld therein must be of goodstrength, not brittle and not have excessive knots or flash thereabout. The number and compositionof the sections of each wire varies considerably although a three-part wire'having sections of "copper wire, of a-special seal wirejand Of n'ickeI- wire,--is most generally iused; On'e' composition of seal wire very generally used tends toweather when subjected to the heat required in'sealing it I to the vitreous parts or thearticle. To protect the wire, a non-conductive 'coatin'g'which isabf sorbed' by the vitreous parts of the seal 'is placed over thewire'. I I

One object of my invention is'toprovide an automaticmachine' for severing lengths froma plurality of wires, for presenting said lengths in end to end relation and for welding said lengths together at a very high rateof speed. Other machines performing these operations are not adapted for such high speed operation, as the distances of travel of the mechanisms and the size and weight of parts thereof are not practicable for such operation. Another object of my invention is to provide a machine for automatically welding lengthsof wire together in-end to end relation and for discharging the sectional f wireformed. Previous machines for welding thewires together had no means for discharging the wire formed but merely allowed it to fall from the mechanismin which it was held during the welding operation. Another object of my invention is to provide mechanism for making an electrical connection to the seal ;wire which is coated except for its ends with ,a non-conductor. Other objects'and advantages of the machine of my invention will appear from the descriptionwhich' follows of one species thereof from the ac- 0 companying drawings.

In the drawings, Fig. 1 is aside elevation-of the i v ,m'achiii'e of my invention; 'Fig.f'2 is 'an end view 01 the mechanism as cutting; supporting and discharging an end length of wire; Fig. 3 is a section along lines 3-4 of Fig. 2; Fig. 4 is an machine ;.Fig.- 9 is a plan view of wire advancing mechanism for both end wire sections or. lengths; Fig. 10 is a perspective view, partially broken away, ofa portion thereof; and Fig. 11 is a ver l0 tical section through a portion of the means for adjusting the vertical position thereof.

The machine of my invention, as shown in Fig. his set up for the manufacture of leading-in wir'esmadeup of. three sections or'lengths of 15 wire- The lengths are taken from wires fed intermittently by mechanism' (not shown) into the mechanism'of my invention, in proper time relation to the opera'tion thereof. Suitable means for feeding the wires is shown'in Patent No. 20 1,213,852 :to'Fa'gan-et al. issued January 30, 1917,- which also provides drivenmembers'to which the mechanisms oi my machine may be connected foroperation. The lengths forming the end sections of the leading inwire'aresevered from a 25 nickel wire HI and a copper wire H which are fed into my machine from the right and left respectively. The nickel and copper wires are operated on by similar mechanisms located to each side of the device which support the lengths 30 of wire taken from said wires in alignment with each other, although located a short distance apart. The length of wire forming the middle section of the leading-in wire is severed from a wire I! fed into my machine from the left to 35 mechanism above and in front of the mechanism operating with the copper wire.- The length of wire taken from wire I! is transferred to a position between the other lengths and is first welded to the nickel wire length and then to the copper 4 Wire length.

In detail, the nickel wire 10, as shown in Figs.

1, 2 and 3, passes through guide l3, between the clamping blocks Hand l5, through the aperture in standard l6 and through the die l'l. With each 45 cycle of operation, clamping block I4 is lifted and the wire is pushed longitudinally through die I! till a'length equivalent to'the end section of the leading-in wire is advamed beyond the die. Clamping block i5 is a stationary member 5 mounted in a channel in standard l6 behind plate I 8 and is supported by bolt I! which is screwed therein and which butts against'gthe standard. Adjustment of the position of block l5.is made by screwing bolt l9 out or in. Clamping block H 56 also lies within the channel in standard I8 and is fastened by pin 29 to slide 2| which is forced downwardly by spring 22. The spring lies within an aperture in the slide and is confined between said slide and the slug 23 which is attached to the plate 24 covering the channel in standard I6 by screw 25. The clamping block I4 is raised from engagement with the wire I9 by a corresponding movement of the slide 2| which is lifted by slide The slide 26engages the disc 21 which is screwed onto an end of slide 2| and is moved vertically in the ways of block 28 by lever 29. The lever 29, which is shown in dotted lines in Fig. 2, engages the slide through roller 39 and is operated about pin 3| in the standard I6 by engagement of roller 32 with cam 33 on the driven shaft 34. The wire advanced beyond die I1, when the clamping block I4 is raised, slides into the groove in the block 35 in drum 36 and is severed from the wire by movement of said die carrying the wire against the edge of knife 31. The knife 31 is mounted on pin 38 in standard I6 whereas the die I1 is mounted in the end of pin 39 in said standard and is attached to arm 49. The movement of die I1 is caused by the passing of roller 4| of said arm 49 (Fig. 1) onto a low part of the cam 42 on the driven shaft 43. The spring 44, which extends between posts in arm 49 and a stationary part of the. machine, causes the roller to follow the cam. In order that the wire may be properLv aimed by the die to pass into block 35, a portion of pin 39 is caused to strike stop block 45. The position of block 45 may be adjusted by moving a wedge (not shown) below said block by turning the bolt 46, which screws into said wedge and is kept from moving by the plate 41. Block 35 is one of a plurality of blocks located in drum 36 which is fastened to washer 48 and which is mounted through engagement of said washer with the disc 49. An aperture in disc 49 fits over a protruding boss of the Geneva gear wheel 59 which is mounted on a portion of the bushing 5| extending beyond the standard I6. The washer 48, disc 49 and Geneva gear wheel 59 are clamped together so as to move with each other by the nut 48' which screws on the bolt 49' extending through the bushing 5|. The wire is kept within the groove of block 35 by another block 52, mounted thereabove, which is fastened to the shoe 53 and insulated therefrom by block 54. The described mechanism and similar mechanism, provided for operation with the copper wire II, each feeds one end of the wire introduced thereby between stud 55 and slide 56 of one arm of the wire advancing mechanism.

Before other operations of these mechanisms take place, the length of wire forming the middle section of the leading-in wire is moved into position between the other lengths of wire.

The seal wire I2 passes into my machine through the aperture in die 51and is fed to the right by mechanism (not shown) which advances a length of wire equivalent to the middle section of the leading-in wire beyond the die. This end of the wire is first gripped by the transferring mechanism shown in Fig. 5 which is mounted on shaft 58 and is then severed from the wire. The transferring mechanism comprises the blocks 59 and 69 which. engage the wire as shown and are mounted in finger 6| and slide 62 respectively. The finger 6| is attached to arm 63 which is fastened to bracket-64 whereas the slide 62 is located in ways in said bracket below plate 65. Bracket 64 is attached to shaft 59 (Fig. 1) which is supported by bracket 66 and holds the mechanism in position to receive the wire as it is advanced beyond the die 51. The wire is gripped through movement of slide 62 which is connected through link 61 and lever 68 to rod 69 which is actuated in proper time relation to the other operations of my machine by mechanism (not shown). Lever 68 lies within the slide ways of bracket 64 and turns about a pin 19 supported by the bracket, and rod 69 lies within the longitudinal aperture in shaft 58 and moves longitudinally therein.

The free end of the seal wire I2 being supported,-the die 51 (Figs. 1 and 4) is moved so the wire is carried against the edge of knife 1| and is severed. The knife 1| is stationary and is mounted through block 12 on the bracket 13 which is mounted on bracket 66. The die 51 is mounted in arm 14 which is attached to pin 15 and is moved by cam 16 through engagement with roller 11. The cam 16 is attached to shaft 18 which is supported by bracket 13 and is turned by mechanism (not shown). attached by pin 19 to block 89 which in turn is attached to arm 14 by screw 8| and which is adapted to be moved vertically after loosening screw 8|, by adjustment of screw 82. The seal wire is cut obliquely by this mechanism.

The seal wire having been severed is now carried down to a position between and in alignment with the other lengths of wire in the welding position. This movement results from movement of the transferring mechanism in which the length of seal wire is held and is produced by rotation of shaft 58, on which the transfer mechanism is.

located, by mechanism not shown. Electrical 83 which is moved into contact with the end of the wire. The edge of said finger strikes the fiat end of the wire, as shown most clearly in the wiring diagram, Fig. 8, in such manner as not to injure the sharp pointed edge of the obliquely cut end thereof. The finger 83 is attached by bolt 84 to an end of arm 85 which in turn is fastened to rod 86 by the insulating bushings 81 and 88 and the collar 89 clamped thereabout. The rod 86 passes through block 99 which pivots on the pin 9| extending between portions of standard 92 and is prevented from moving longitudinally in said block by collars 93 and 94. The vertical position of the finger 83 is controlled by cam which engages roller 96 in the end of rod 86 and moves the assembly against the contracting force of spring 91 which is located between posts in rod 86 and standard 92. The force with which the finger 93 contacts the wire is produced by cam 98 which is engaged by roller 99 and turns the assembly about in block 99. An opposite turning force is produced by spring 91 which holds the roller against the cam. The roller 99 is attached to lever I99 which is pivotally mounted by pin I9| in the arm |92-extending from rod 86. The force with which the finger 83 contacts the wire is controlled by spring I93 which is located between an end of said lever and said arm and permits lever |99 to turn should the force be great enough to contract the spring. When no force is applied, the lever I99 is held in position by nut I94 on the stud I95 extending from arm I92. which is turned by mechanism not shown.

Connection having been made to the seal wire, the nickel length of wire I9 is also connected into the welding circuit and is moved so the ends of said wires contact and are welded together. Both The' roller 11 is Cams 95 and 98 are mounted on shaft I96- these operations are performed by the wire adformer weld is made and the seal wire contacting mechanism has'been withdrawn. In each instance, the operations are performed by similar mechanisms, which are built'to'gether as a unit.

In both cases the wire which is located between a stud 55 and the teeth of slide 56, as shown in Fig. 10, is clamped therebetwen by movement of said slide. The stud 55 extends from arm I01, which is attached to-bracket I08 and provides ways in which the slide 56 is located. The slide is confined within said ways by plate I09 and the bracket I88 and is moved by the toggle joint which comprises links IIO and III, blocks H2 and H3 and yoke H6. Block H2 is attached to the slide 56 and block I I3 is prcvidedwith a stud screwed in nut II6, the flange II1 of which is held in grooves in bracket I08. A cover plate 8- holds the blocks and nut H6 in the ways in bracket I08. Means (not shown) acting through rod I I9 and yoke I I5 operate the clamping mechanism. Each mechanism is connected into the welding circuit by wires (not shown) so that the engagement of the lengths of wire therewith makes theconnection thereto.

After the wires have been gripped by the advancing mechanism, said mechanism is movedso the ends of the wires are brought together. The movement occurs as bracket I08 isturned about the supporting means for the studs I20 and I 2I which extend from opposite sides-therefrom. As shown in Fig. 9, the bracket is engaged through pin I22 and insulating washer I23 by rod I24 which swings the mechanism as required. The

rod is operated by mechanism (not shown) whereas the studs I20 and I2I are each supported by a ball bearing I25 in an arm of yoke I26 which permits said movement. The yoke I26 is mounted on studs I21 and I28 about which it is adapted to be turned to raise and lower the clamping means as required with the different wire sizes used. Means are also provided for moving the yoke sidewise on said studs to line up the mechanism in this direction. The yoke sup porting studs I21 and I28 of each clamping mech anism are supported by bracket I29 through bracket I30 in one case and brackets I3I and I32 in the other. The sidewise movement is produced in each case through movement of a collar I33 which is confined in a slot in the block I33? extending from the yoke and is moved back and forth as the rod I34 is screwed in and out of the bracket I35 extending from bracket I29. The rotation of rod I34 is secured by manual rotation of wheel I36 whichis mounted on the insulating members I31 and which is clamped to said rod by nut I38. ,Meansare provided for locking" the rod in any 'position,.which is comprised of the slug I3.9,' the wedge, I40, the threaded stud HI and the knob I42. .When it is desired to lock the rod I34 inposition, knob I42 is turned clockwise, which screws stud I4I in and forceswedge I against slug I39. The slug is forced against the wall of bracket I35 preventing rod 134 from turning. The means for moving the yoke vertically is very. similar to the other adjustment means, in that a rod I43. is screwed inand out of bracket-I44 by manual rotation of lever I45 which is attached tosaid rod and duplicate means is provided for locking the rod-in any position which is operated by knob I46. The inner end of the rod I43 in this case, as shown in Fig. 11, engages, through a flange I41, a wedge I48 located in an aperture in bracket I29 which moves the block I49 upon which the yoke I26 rests. Bushing I50 is 'slidably'mounted on rod I43 and in the aperture in bracket I29. 'Since 5 the mechanisms are both connected to the welding circuit, they are insulated from each other and from the machine." The formeris produced'by separating the halves of bracket I29 in which said mechanisms are located by the 10 strip of insulating material I5I and the latter is produced by insulating the bracket I29 from the machine by other insulating members not shown.

The welding circuit is featured by switching 5 means operated in proper relation to the movement of the other portions of the machine and is shown in Fig. 8. In this instance, three switches I56 and I51 are charged since cams I52 and I53 cause bars I 58 and I59 to engage contacts I60--I6I and I62--I63 respectively. The welding current is taken from a source of direct our- 25 rent electricity, the positive lead of which is connected directly to the condensers I56 and I51 and the negative lead of which is connected in one instance through the lamp I64, contact I60, bar I 58 and contact I6I to condenser I56, and 30 in the other instance through the lamp I65, contact I62, bar I59 and contact I63 to condenser I51. Each contact is mounted on a pin I66 held by a guide I61 and has between the head thereof and said guide a spring I68 which produces the 35 contacting pressure as pin I66 is free to move The bars are insulated from the roller I69 by an insulating'member I10 therebetween. The condensers'a're now connected to the variouslengths of wire so the welds are made as they are brought in contact with each other. These connections are made through the polarity reversing switches HI and I12 which are set in one position and are not changed during the welding operation. In one arrangement, the lead from condenser I51, which was connected to the negative lead, is not connected to the nickel wire I0 through the contact I13, the bar I59 which is then in contact, therewith, contact I14, the reversing switch I12 and the wire advancing mechanism; The positive lead is connected to the seal wire I2 through 55 .the'variable'resistance I15, contact I16,'bar I11 which is then moved into engagement therewith,

contact In, reversing switch m and the seal 'anism now moves'away and the leads from condenser I56 are connected to the nickel and copper lengths of wire. The lead from condenser I56, which was connected to the negative lead, is now connected to the copper wire II through contact I19, barv I59 in contact therewith, contact I86, the reversing switch "I and the wire advancing mechanism. The nickel wire is connected to the positive lead through the variable resistance III, contact I82, the bar I11 then in contact therewith,'contact I83, reversing switch I and the wire advancing mechanism. Obviously,-the polarity of the mechanism may be changed as deblocks I85, I86 and I81, which are connected to sired and the resistance members may be in more than one unit if found more desirable without passing from the scope of this invention. On stopping the machine, the condensers are shortcircuited by switch I84 so that they may not be discharged accidentally. or remain charged when the machine is idle. The switch comprises three the negative leads of condensers I56 and I 51 respectively and to the positive lead, and the said switch is closed when plate I88 is in engagement with all three blocks. The switch I84 is closed after the direct current connection to the machine is broken and is closed preferably with the same manual operation.

The lengths of wire now having been welded together, the discharge of the three part sec-1 tional wire is now effected. The first step in said operation is the release of the seal wire from the transfer mechanism which then returns to a position before the cutting mechanism therefor.

The second step of said operation occurs as the drums 3636 holding the nickel and copper lengths of wire are indexed one position so as to advance another block 35 into position in eachcase. The sectional wire is then'still trapped by.

shoe 53 within the grooves of the block 35 in which it is located, but repeated indexes cause it to pass from under said shoe and to be forced out by plates I89. The indexing results from engagement of Geneva gear wheel 50 with the Geneva gear I90 which is mounted on shaft 34. The shaft 34 is driven by shaft 43 through gears I 9| and I92 which'mesh together. Shaft 34 turns in block I93 which supports standard Hi.

What I claim as new and desire to secure by Letters Patent of vthe United States is:

1'. A machine for welding a pair of wires together in end to end relation, comprising means for supporting two wires in-alignment with welding ends spaced apart, means, located adjacent on the opposite side thereof from'the welding 'end of said wire, for severing from said wire a length to be held by its supporting means, means for connecting said length of wire and the other supported wire in an electrical circuit, and means, separate from said supporting means, engaging said length of wire for advancing it toward the other wire until the ends thereof meet and are welded together. v

2. A- machine for welding a pair of wires together in end to end relation comprising separate means for supporting each of said wires, at least one of said supporting means comprising a block having a groove therein adapted to receive a portion of one of said wires and support it in align-- ment with and with a welding end thereof spaced from the welding end of a wire held by the othersupporting means, means for connecting said wires in an electrical circuit, means located ad-- jacent the end of said block opposite from the said welding end for severing a length from said wire, means engaging the wire in the groove, after it is severed, for advancing it toward the other wire to cause the end thereof to strike the end of said other wire and to be welded thereto.

3. A machine for welding a pair of wires together in end to end relation comprising separate means for supporting each of said wires, at least one of said supporting means comprising adrum having a plurality of grooves in the periphery thereof, each adapted to support in turn a length of wire in alignment with and with an end thereof spaced from a wire held by the other supporting means, means for connecting said wires in an electrical circuit, means engaging the wire insaid groove for advancing it so that ends of each of said wires contact and are welded to-- gether and means for thereafter-indexing said drum to bring another groove into welding position.

4. A machine for welding a plurality of lengths of wire together in end to end relation, comprising means for supporting said wire lengths in alignment and spaced apart, means for connecting said wire lengths in-an electrical circuit, means independent of said, supporting means for engaging one of said wire lengths and. advanc ing said length toward a second length of wire until ends of said. lengths meet and are welded together, and separate means engaging a third wire length .for advancing it until its end meets the other end of said second wire length and is welded thereto.

5. A machine for welding a plurality of wires together in end to end relation comprising means for supporting two wires in alignment and with welding ends spaced apart, means, located adjacent eachof said means and on the opposite sides thereof from the welding ends of said wires, for severing from the wires the lengths to be held by their supporting means, means, located adjacent the supporting means for other wires, for severing a length from a third wire, trans-' ferring means forcarrying said wire length to a position between and in alignment with the other wire lengths, means for connecting the wire lengths in an electric circuit and means independent of said supporting means for engaging each of the two outer wire lengths and advancing them toward the middle wire length until the welding ends thereof meet the respective ends of the middle wire length and are welded thereto.

6. A machine for welding a plurality of lengths of wire together in end to end relation comprising separate means for supporting each of three wires, two of said supporting means each comprising a drum having a plurality of grooves in the periphery thereof, each groove adapted to support in turn a length of wire in alignment with and with an end thereof spaced from a third wire held by the third supporting means, means for connecting said wires inan electrical circuit, means independent of and supportirig means for engaging each of the wire lengths held in aligned grooves of said drums in welding position for advancing them so thatan end of each contacts an end of the third wire and is welded thereto and means for thereafter indexing said drums to bring other grooves therein into the welding position.

7. A machine for welding a plurality of wires together in end to end relation comprising means 7 for supporting three wires in alignment with the welding ends of the outer wires each separated from the adjacent end'of the middle wire, means, for connectingthe middle wire in an electrical circuit, comprising a finger, means for moving other of said outer wires in an electrical circuit and for advancing said wire, after the finger has been withdrawn, until the welding end thereof meets the other end of the said middle wire and is welded thereto.

8. A machine for welding a plurality of wires together in end to end relation comprising means for supporting each of three wires, two of said supporting means each comprising a drum having a plurality of passages in the periphery thereof, each passage adapted to hold in turn a length of wire in alignment with andwith an end thereof spaced from a wire held by the other drum, severing means located adjacent to each of said drums for cutting that length of wire in said passage from the remainder, severing means located adjacent to said supporting means for said third wire, transferring mechanism located adjacent to said severing means adapted to carry the said third wire length thus severed into position between the ends and in alignment with said other wires, means for connecting one end of said third wire length in an electrical circuit, means for gripping the length of wire adjacent to the other end of said third wire length to connect it in an electrical circuit and for moving it toward said third wire length until the ends of said wires meet and are welded together, means for gripping the remaining wire length to connect it in an electrical circuit and for moving it so that its end contacts the unwelded end of said third wire length to cause said lengths of wire to be welded together, and means for indexing said drums to remove the welded wire and to bring the next drum passages into operative positions.

9; A machine for welding a plurality of wires together in end to end relation comprising means for supporting two wires in alignment and with welding ends spaced apart, means, located adjacent to each of said supporting means and on the opposite sides thereof from the welding ends of said wires, for severing the length of each to be held by its supporting means, means, located adjacent to the supporting means for the other wires, for severing a length from a third wire, transferring means for carrying said wire length to a position between the ends and in alignment with the other wire lengths, means comprising a finger and means for moving said finger into contact with one end of said third wire length to connect said length in an electrical circuit, means for gripping the length of wire adjacent to the other end of said third wire length to connect it in an electrical circuit and for moving it toward said wire length until the ends of said wires meet and are welded together, means for gripping the remaining wire length to connect it in an electrical circuit and for moving it so that its end .contacts the unwelded end of said third wire length after the aforesaid finger has been removed to cause said lengths of wire to be welded together.

10. A machine for welding a plurality of wires together in end to end relation comprising separate means for supporting each of three wires, two of said supporting means each comprising a drum having a plurality of passages in the periphery thereof, each passage adapted to hold in turn a length of a wire in alignment with and with an end thereof spaced from a wire held by the other drum, severing means located adjacent to each of said drumsfor cutting that length of wire in said passage from the remainder, severing means located adjacent to said supporting means for said third wire, transferring mechanism located adjacent to said severing means adapted to carry the said third wire length thus severed into position between the ends and in alignment with said other wires, means comprising a finger and means for moving said finger into contact with one end of said third wire length to connect said length in an electrical circuit, means for gripping the length of wire adjacent to the other end of said third wire length to connect it in an electrical circuit and for moving it toward said third wire length until the ends of said wires meet and are welded together, means for gripping the remaining wire length to connect it in an electrical circuit and for moving it so that its end contacts the unwelded end of said third wire length after the aforesaid finger has been removed to cause said lengths of wire to be welded together, and means for indexing said drums to remove the welded wire and to bring the next drum passages into operative positions. 

